An automated method and system for shell-shaped dental instrument production

Abstract

The application discloses a kind of shell dental instrument automated production method and system, it is related to dental medical instrument automation production and industrial control technical field.The method takes merging object as control unit, and the production flow and output process of shell dental instrument from forming model to finished product are automatically organized, the identification mapping relationship across process is established, and combined with the classification forming under shared production path, identification coding, asynchronous buffer sorting and merging output control, the automated production of different forming demand shell dental instrument is realized.The present application can improve the traceability continuity in production process, reduce end sorting pressure.

Description

Technical Field

[0001] This invention relates to the field of automated production and industrial control technology for dental medical devices, and particularly to an automated production method and system for shell-shaped dental instruments. The shell-shaped dental instruments refer to instruments obtained by thermoforming a diaphragm onto a dental model, used to cover the dentition or jaw area, including clear aligners, retainers, accessory templates, and other dental instruments with a shell-shaped covering structure. Background Technology

[0002] Invisible aligners are customized dental instruments designed and manufactured based on individual patient dental data. They are typically formed by thermoforming a thermoplastic film onto a dental model. Unlike standard industrial products, invisible aligners are not manufactured as single parts, but as a set of deliverables based on a patient's case. A complete case usually includes multiple aligners for various treatment steps, and may also include accessory templates, retainers, and other auxiliary components; different components often differ in material form, thickness specifications, molding processes, and post-processing requirements. Current industrial production typically employs a manufacturing execution system (MES) to receive orders, perform 3D printing scheduling, perform post-processing, molding, marking and cutting, and finally sorting and packaging.

[0003] However, there are significant differences between invisible aligner production lines and ordinary industrial assembly lines. Ordinary industrial products are often organized around single pieces, single batches, or homogeneous components, focusing more on single-station efficiency, equipment saturation, or batch cycle time. In contrast, the true delivery object of an invisible aligner production line is the "case," and a single case simultaneously involves multiple steps, multiple components, strong sequential dependencies, and high traceability requirements. In other words, the stable operation of this type of production line depends not only on the instantaneous capacity of individual stations such as printing, lamination, and marking, but also on whether cases can maintain orderly progress within the rhythmic windows corresponding to their respective processes during cross-process flow, and whether the number of cases waiting for order consolidation and sorting at the end remains within a controllable range. If only the utilization rate of a certain process is maximized without a coordination mechanism for case-level flow order and buffer limits, it is easy to accumulate sorting pressure at the back end, thus affecting the stability of the entire line. This contradiction is a key technical characteristic that distinguishes invisible aligner production lines from ordinary industrial production lines.

[0004] In existing technologies, to improve the utilization rate of 3D printing platforms, dental models from multiple different cases are typically mixed and arranged, allowing models from different cases to be distributed simultaneously on the same printing base or in the same production batch. Subsequent processes such as cleaning, curing, lamination, cutting, and sorting are then used to complete production. While this approach improves the utilization rate of local equipment, it also causes cases to be broken up early in the process flow, resulting in different cases and components continuously overlapping in later stages of the process. Ultimately, this concentrates the pressure of sorting, classifying, and reordering at the end of the production line. Especially in cases of reordering, rework, or delays in a certain step, the integrity of the cases is further compromised, easily leading to a situation where some components arrive first and others lag behind, significantly complicating the end-of-line caching and sorting logic.

[0005] Furthermore, there is often a coexistence of heterogeneous components within clear aligner cases. For example, standard aligners are typically formed continuously using rolled films, while accessory templates or retainers may require sheet films of different materials or thicknesses. Existing lamination equipment is mostly designed for a single material form, suitable only for either rolled or sheet materials. This forces different components for the same case to be produced separately on different equipment, in different processes, and even at different times, before being reassembled at the end. While this achieves separate processing at the equipment level, from the perspective of case-level flow, it further exacerbates the problems of case disassembly, component misalignment, and difficulties in final merging. The essence is not merely equipment incompatibility caused by material differences, but rather the lack of a collaborative mechanism in current technology that can simultaneously accommodate the co-line production of heterogeneous materials and the orderly flow of cases.

[0006] Furthermore, as a customized product for clinical delivery, invisible aligners place high demands on identification and end-to-end traceability during the production process. Current technologies commonly involve affixing QR codes or RFID tags to dental models, carriers, or tooling, and then re-coding the diaphragm or finished product after lamination. The problem lies in the fact that the process between the model and the final diaphragm product typically involves multiple steps such as demolding, transport, lamination, and cutting. If the transfer of product identification relies on pure software matching, workstation inference, or secondary re-pairing, mismatches between model and product information can easily occur due to mechanical failures, sensor errors, batch mixing, or human intervention. For such customized medical products, this break in the traceability chain is not merely a general production management issue, but a technical problem directly related to delivery accuracy and quality control reliability.

[0007] It should also be noted that existing production lines often lack the dynamic recovery capability for case integrity when handling abnormal operating conditions. For example, if a model is rejected in the post-processing, lamination, or quality inspection stages, the replacement unit usually needs to be re-inserted into a subsequent batch, thus creating a significant time misalignment with other components of the original case. If the system still controls the flow according to single-unit or single-station logic, completed components can only accumulate at the end, causing the buffer channel to be occupied for a long time and rapidly increasing the pressure at the sorting end. In other words, what the invisible aligner production line really needs to solve is how to keep the number of cases in production and the end-of-line sorting pressure under the conditions of multiple cases proceeding in parallel, multiple components completing asynchronously, and the continuous existence of abnormal operating conditions.

[0008] Therefore, existing technologies urgently need a new automated production technology solution for invisible orthodontic appliances. This solution should not only aim to maximize the capacity of a single station, nor should it be limited to order scheduling or information system management. Instead, it should focus on the actual delivery object—the case-level circulation—and, through cross-process rhythm coordination, co-line processing of heterogeneous components, physical inheritance and traceability of identification, and controlled buffer release mechanisms, enable multiple cases to proceed in parallel on the same production line, while limiting the number of cases awaiting sorting at the end to a manageable threshold. This establishes a stable balance between production efficiency, traceability reliability, and sorting pressure. Summary of the Invention

[0009] The purpose of this invention is to provide an automated production method and system for shell-shaped dental instruments, addressing the problems inherent in existing technologies where different cases, various components, and heterogeneous membrane types are mixed and produced on the same production line. These problems easily lead to disordered flow between upstream and downstream processes, excessive end-of-line sorting pressure, difficulties in order recovery, and easy breakage of the product traceability chain. Through the technical solution of this invention, the production flow and output process of shell-shaped dental instruments from molding model to finished product can be automated, centered around the merged object. Under a shared production path, instruments with different molding requirements can be classified and molded. Furthermore, through cross-process identification mapping continuity and rhythmic coordination based on the merged state, controlled output of the merged object can be achieved.

[0010] To achieve the above objectives, the present invention provides an automated production method for shell-shaped dental instruments. In one possible embodiment, the method uses a merging object as a control unit, receives order information and determines the merging object; generates production scheduling tasks for multiple molding models, assigns multiple molding models corresponding to the merging object to one or more printing base plates and establishes a binding relationship between the printing base plate identifier and the model position and instrument attributes, and simultaneously forms a first identification feature on the molding model as a model identity identifier; performs 3D printing and post-processing on the multiple molding models; transfers the post-processed molding models to a buffer carrier in a predetermined order, and establishes a binding relationship between the first identification feature, the buffer carrier identifier, and the grid position information; and sends the molding model into... The molding unit, based on the instrument attributes, distributes the instruments to at least two molding stations for thermoforming. These at least two molding stations share an input channel and an output channel. During thermoforming, a first identification feature set on the molding model forms a second identification feature on the molding sheet. The second identification feature is identified and verified based on the aforementioned binding relationship. After successful verification, the molding sheet is assigned a final traceability identifier and cut to form a shell-shaped dental instrument. The cut shell-shaped dental instrument is then sent to an asynchronous buffer sorting unit, where it is cached according to the merged objects. When the merged objects are complete, a merge output is executed; when a merged object is missing parts, a logical suspension is executed, and the instrument waits for replacement.

[0011] In one possible implementation, the merging object is a single case or a combination of multiple cases for unified merging output. Accordingly, during the production scheduling stage, multiple molded models corresponding to the same merging object can be arranged in a spatially proximate manner in a continuous or adjacent area of ​​the same printing base plate to reduce the order disorder and sorting pressure caused by model mixing during subsequent flow.

[0012] In one possible implementation, the print base plate identifier is a first RFID tag disposed on the print base plate, and the buffer carrier identifier is a second RFID tag disposed on the buffer carrier. By establishing board-level binding relationships during the print base plate stage and establishing carrier-level and grid-level binding relationships during the buffer transfer stage, the conversion from board-level tracking to single-piece-level tracking can be achieved.

[0013] In one possible implementation, the first identification feature is located in a non-functional area of ​​the molded model, preferably a raised unique identification feature; the second identification feature is a recessed inherited identification feature formed on the inner side of the diaphragm after hot pressing. By incorporating the first identification feature as part of the geometry of the molded model into the hot pressing replication, the physical inheritance of the model identity to the diaphragm identity can be achieved without relying on temporary re-coding after pressing.

[0014] In one possible implementation, the at least two lamination stations include a first lamination station for processing roll-type diaphragms and a second lamination station for processing sheet-type diaphragms, wherein the second lamination station selects sheet-type diaphragms of different materials and / or different thicknesses based on the instrument's properties. Thus, shell-shaped dental instruments corresponding to different diaphragm types can be classified and formed within a shared production path without needing to be processed separately off the main line.

[0015] In one possible implementation, a visual recognition module is used to identify the first identification feature and / or the second identification feature; after the second identification feature passes verification, a final traceability identifier is formed at a predetermined position on the membrane. The final traceability identifier is preferably a permanent identifier capable of representing patient information, procedure information, and / or batch information.

[0016] In one possible implementation, the asynchronous buffer sorting unit includes multiple independently controlled buffer channels; when a defective or missing part is detected under a certain merging object, a replacement task is generated and the replacement task is preferentially inserted into the available printing batch closest to the current time; at the same time, the shell-shaped dental instruments that have arrived under the merging object are placed in a logical suspension state, and the logical suspension is lifted and the merging output is executed after the replacement part arrives.

[0017] In one possible implementation, the manufacturing execution system adjusts the task release rhythm, buffer carrier transfer rhythm, and / or film diversion rhythm of at least one upstream process based on the status information of the asynchronous buffer sorting unit, so as to ensure that the number of objects in the merging state does not exceed a preset threshold N. This closed-loop coordination based on merging state allows the production flow process to match the end-of-line merging output capacity, reducing the accumulation of end-of-line sorting pressure caused by order replenishment, rework, and time differences in the arrival of different equipment.

[0018] The present invention also provides an automated production system for shell-shaped dental instruments. In one possible embodiment, the system uses the merging object as the control unit to automatically organize the production flow and output process of shell-shaped dental instruments from molding model to finished product. By maintaining the continuity of cross-process identification mapping and rhythmic coordination according to the merging status, the system enables shell-shaped dental instruments corresponding to different molding requirements to complete classification molding and merging output under a shared production path.

[0019] In one possible implementation, the automated production system for shell-shaped dental instruments includes a manufacturing execution system, a 3D printing unit, a post-processing unit, a buffer transfer unit, a molding unit, an identification and coding unit, a cutting unit, and an asynchronous buffer sorting unit. The manufacturing execution system receives order information, determines merging objects, generates production scheduling tasks, establishes identification binding relationships, and issues control commands. The buffer transfer unit transfers the post-processed molded models to a buffer carrier in a predetermined order and establishes a binding relationship between a first identification feature, a buffer carrier identifier, and grid position information. The molding unit includes at least two molding stations sharing an input channel and an output channel, used for thermoforming according to the instrument attributes corresponding to the molded model, and forming a second identification feature on the molded model onto a diaphragm based on the first identification feature. The identification and coding unit identifies the second identification feature and verifies it based on the identification binding relationship, forming a final traceability identifier after successful verification. The asynchronous buffer sorting unit buffers the cut shell-shaped dental instruments according to the merging objects, performs merging output when the merging objects are complete, and performs logical suspension and waits for replacement when the merging objects are missing parts.

[0020] In one possible implementation, the buffer transfer unit includes a transfer robot, a vision recognition module, and a multi-compartment buffer carrier; the pressing unit includes a first pressing station for processing roll film and a second pressing station for processing sheet film, and the second pressing station includes a sheet material bin that can switch between different sheet specifications.

[0021] In one possible implementation, the manufacturing execution system is further configured to adjust the task release rhythm, buffer carrier transfer rhythm, and / or pressure film diversion rhythm of at least one upstream process based on the status information of the asynchronous buffer sorting unit, so as to ensure that the number of objects to be merged is not greater than a preset threshold N.

[0022] Compared with the prior art, the present invention has at least the following beneficial effects: by using the merged object as a control unit, the scheduling, printing, post-processing, buffer transfer, classification and molding, identification and coding, cutting, and asynchronous buffer sorting are integrated into a unified organization, which can realize the automated production of shell-shaped dental instruments with different molding requirements under a shared production path; by establishing a physical inheritance identification transfer relationship between the molding model and the diaphragm, the continuity and reliability of cross-process identity traceability can be improved; through asynchronous buffer sorting, logical suspension, supplementary order insertion, and rhythmic feedback adjustment based on the merged state, the end-of-line sorting pressure can be reduced and the recovery capability under abnormal working conditions can be improved. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the overall structure of the shell-shaped dental instrument automated production system of the present invention.

[0025] Figure 2 This is a schematic diagram of the printing base plate's neighboring production scheduling and base plate-level identification binding in this invention.

[0026] Figure 3 This is a schematic diagram of the single-piece transfer and buffer carrier binding after the post-processing of the molded model in this invention.

[0027] Figure 4 This is a schematic diagram of the dual-station pressing unit in this invention.

[0028] Figure 5 This is a schematic diagram illustrating the working principle of the shunt pressing unit in the present invention.

[0029] Figure 6a This is a schematic diagram of the raised marking feature set on the molding model in this invention.

[0030] Figure 6b This is a schematic diagram showing the state of the diaphragm after hot pressing and before cutting in this invention.

[0031] Figure 6c This is a schematic diagram of the recessed inheritance marking feature formed on the inner side of the membrane in this invention.

[0032] Figure 7 This is a schematic diagram of the entire process identification transmission chain and traceability binding relationship in this invention.

[0033] Figure 8 This is a schematic diagram of the asynchronous buffer sorting and merging release states in this invention.

[0034] Figure 9 This is a schematic diagram of the near-position insertion of supplementary single components and the self-healing control of disordered order in this invention.

[0035] Figure 10 This is a schematic diagram showing the different shell-shaped dental instruments to which this invention is applicable and the corresponding diaphragm types.

[0036] Figure 11 This is a schematic diagram of rhythm feedback and threshold control of the number of items to be merged in this invention. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the following specific examples illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. This application can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application. It should be noted that, in the absence of conflict, the following embodiments and features in the embodiments can be combined with each other. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0038] In this specification, a merged object refers to an object that needs to be released, packaged, or output as a whole at the end of the production process. The merged object can be a single case or a combination of multiple cases determined based on a unified merged output rule. This invention is not limited to the merged object being equivalent to a single case, but rather focuses on maintaining merged integrity during the production process and achieving controlled output at the end.

[0039] In this specification, identifier mapping continuity refers to the traceable correspondence between physical objects in different processes of a shell-shaped dental instrument, from model generation, printing, post-processing, buffer transfer, molding, identification and coding to finished product output. This correspondence can at least be manifested as a mapping relationship between the printing base plate identifier, model identifier, buffer carrier identifier, inherited identifier features, and the final traceability identifier. Preferably, the aforementioned mapping relationship is recorded and maintained by the manufacturing execution system and used for identification, verification, diversion, buffering, and release control in subsequent processes.

[0040] In this specification, a shared production path refers to the fact that shell-shaped dental instruments with different molding requirements complete their flow within the same overall production path, and undergo differentiation processing at at least one stage based on instrument attributes, diaphragm type, or functional requirements. This differentiation processing preferably manifests as different molding models entering different pressing stations for thermoforming, but the present invention is not limited to this specific form.

[0041] In this specification, the merge state refers to the arrival completeness state of a merged object at the end of production or in the buffer stage. The merge state includes at least a complete state and a missing parts state; specifically, when all target devices under the merged object have arrived, the merge state is complete; when there are still devices that have not arrived, are reworked, are in supplementary orders, or are pending replenishment under the merged object, the merge state is missing parts. Preferably, when the merge state is missing parts, the arrived devices corresponding to that merged object enter a logical suspension state, and are released from suspension and merge output is executed after replenishment is completed.

[0042] In this specification, the asynchronous buffer sorting unit refers to a functional unit used for buffering, suspending, filling in, and releasing cut shell-shaped dental instruments according to their grouping objects. The asynchronous buffer sorting unit does not require instruments under the same grouping object to arrive synchronously, but allows instruments to enter their corresponding buffer positions at different times, and the manufacturing execution system determines whether to perform the grouping output based on the grouping status.

[0043] In this specification, closed-loop coordination refers to the manufacturing execution system adjusting the task release, buffer transfer, or pressing execution rhythm of at least one upstream process based on the status information of the merged objects in the asynchronous buffer sorting unit, so as to match the production process with the end-of-line merging output capacity. The closed-loop coordination is preferably used to limit the number of merged objects in the merging state and reduce the accumulation of end-of-line sorting pressure caused by order replenishment, rework, order insertion, or time differences in the arrival of different equipment.

[0044] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. It should be understood that the following embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit the scope of protection of the present invention.

[0045] In one embodiment, Figure 1 This invention illustrates the overall flow of an automated production method and system for shell-shaped dental instruments. The shell-shaped dental instruments are dental instruments obtained by thermoforming a dental molding model using a diaphragm, preferably but not limited to clear aligners, retainers, and accessory templates. The system constructs an end-to-end automated process around receiving patient orders, model processing, 3D printing, post-processing, molding, identification and coding, cutting, and asynchronous buffered sorting and merging output. Through a unified digital identification management and equipment scheduling mechanism, the shell-shaped dental instruments maintain a predetermined order during production, complete the co-line processing of heterogeneous materials, and achieve merging output at the end.

[0046] In this embodiment, the system includes a manufacturing execution system, a 3D printing unit, a post-processing unit, a buffer transfer unit, a molding unit, an identification and coding unit, a cutting unit, and an asynchronous buffer sorting unit. The manufacturing execution system receives order information, manages model identifiers, generates production schedules, issues control commands to each execution device, and records end-to-end traceability data. The 3D printing unit prints dental molding models. The post-processing unit performs spin drying, curing, and demolding of the entire mold. The buffer transfer unit converts model flow from plate-level to single-piece-level flow. The molding unit selects the appropriate mold type for thermoforming based on the instrument attributes of the model. The identification and coding unit verifies the identity of the molded mold and assigns a final traceability code. The cutting unit cuts the mold into target shell-shaped dental instruments. The asynchronous buffer sorting unit performs case-level caching, missing part detection, logical suspension, release after replenishment, and final merging and output of each instrument.

[0047] Furthermore, the Manufacturing Execution System (MES) can include an order management module, a model processing module, a production scheduling control module, and a marking control module. The order management module receives patient case submissions and creates production orders; the model processing module generates standardized model data with unique identifiers; the production scheduling control module generates printing tasks based on patient case sequence, printing equipment status, and subsequent process cycle times; and the marking control module generates corresponding traceability identification data and controls marking execution after successful identification and verification. Through the collaboration between these software modules and hardware devices, a closed-loop automated production system covering the entire process—from patient case submission and order creation to model processing, 3D printing, post-processing, lamination, cutting, marking, and packaging—is formed.

[0048] like Figure 1 As shown, at the initial stage of the process, the system first receives case order information and determines the corresponding production merging object. In a preferred embodiment, the merging object is a single case, thereby allowing the orthodontic appliances, retainers, and accessory templates for each step under the same case to flow as continuously as possible in subsequent processes. In other embodiments, it is also allowed for a case to be assigned across multiple printouts, or for multiple cases to share the same printout, but the manufacturing execution system still distinguishes and tracks each model through a unique digital identifier to maintain the consistency between the digital sequence and the physical flow, avoiding the sequence disorder caused by manual sorting in traditional production methods.

[0049] During the scheduling and printing phases, the Manufacturing Execution System (MES) generates model layout data based on order information and assigns uniquely identified molded models to one or more printing base plates. In a preferred embodiment, models from the same case are preferentially arranged in adjacent areas to ensure sequential flow in subsequent processes; simultaneously, a base plate-level binding relationship is established between the printing base plate and the batch of models. Subsequently, the 3D printing unit prints multiple molded models according to the scheduling task, thereby obtaining dental molded models for subsequent thermoforming. Through unified management of base plate positions, model positions, and digital identifiers, even if models are produced in parallel across multiple printers or multiple base plates, they can still maintain a logical correspondence consistent with the original digital sequence in subsequent processes.

[0050] After printing is completed, the printing base plate enters the post-processing stage. In one embodiment, an automated guided vehicle picks up the plates sequentially according to a predetermined production schedule and transports them to the post-processing equipment to keep the physical flow sequence synchronized with the digital production sequence. During post-processing, the molded models preferably maintain their original arrangement on the base plate and are not prematurely broken up in the previous process. The post-processing equipment can sequentially perform operations such as spin drying, curing, and whole-plate demolding. The whole-plate demolding can be achieved by using a multi-hole base plate with a synchronous lifting method using an ejector pin array to detach the model without disrupting the original sequence. In this way, the models carried on the base plate can continue to maintain their original sequence during post-processing and transportation, creating conditions for subsequent single-piece bonding.

[0051] After post-processing, the process enters the buffer transfer stage. The buffer transfer unit transfers multiple molded models on the base plate to a buffer carrier with multiple slots in a predetermined order. During the transfer process, the unique identifier on the model is identified, thereby establishing the correspondence between the model identifier, the buffer carrier identifier, and the slot position information. Through this process, the system realizes the transformation from base plate-level flow to single-piece-level flow, that is, from the tracking method of "one base plate corresponding to multiple models" to the tracking method of "one model corresponding to one carrier slot," thus providing a single-piece-level data foundation for subsequent automatic diversion and molding according to instrument attributes.

[0052] like Figure 1As further shown, the buffer carrier then enters the lamination stage. In one embodiment, the lamination unit is a dual-station lamination machine, which can call different film materials according to the instrument type corresponding to the model. For standard orthodontic appliances, roll film can be used for thermoforming; for retainers, accessory templates, or other shell-shaped dental instruments, sheet film of different materials or thicknesses can be used for thermoforming. The manufacturing execution system issues diversion instructions based on the model's unique identifier and its instrument attributes, allowing different models to enter the corresponding station on the same main line to complete lamination, thereby avoiding the manual decoupling problem caused by the inability of roll and sheet materials to be produced on the same line in the prior art. The system can automatically call the corresponding material bin according to the model ID to realize multi-material collaborative processing.

[0053] During the lamination process, the first identification feature on the model is preferably transformed into a second identification feature on the diaphragm through a thermoforming physical process. This achieves the natural inheritance of identity information from the model to the diaphragm without adding any additional marking steps. After lamination, the diaphragm and model assembly enters the identification and coding stage. The identification and coding unit reads the second identification feature and compares it with the production scheduling data and model attributes recorded in the manufacturing execution system. After successful verification, the diaphragm is assigned a final traceability identifier. Subsequently, the cutting unit cuts the diaphragm according to a preset cutting path to form the target shell-shaped dental instrument. Through the above process, the model identifier, the inherited identifier, and the final traceability identifier can be connected to construct a continuous traceability chain.

[0054] After cutting, the shell-shaped dental instruments enter the asynchronous buffer sorting stage. In one embodiment, the asynchronous buffer sorting unit includes multiple buffer channels. The manufacturing execution system allocates the instruments to the corresponding buffer positions based on the patient information, component information, or preset merging rules. When all instruments under a certain patient or preset merging object have arrived, the system triggers a merging output; when there are missing parts, the arrived instruments enter a logical suspension state and are not released temporarily, but this does not affect the continued operation of other channels. For rework or replacement parts, the system can guide them to the corresponding channel after re-identification and minimize the replacement time by using a proximity insertion method.

[0055] like Figure 2 As shown, in one embodiment, Figure 2 This invention illustrates the implementation of print base plate proximity scheduling and base plate-level identification binding. This stage, located after order information reception and before 3D printing execution, is mainly used to allocate the molding models corresponding to multiple shell-shaped dental instruments included in the case order to one or more print base plates according to a predetermined flow logic, and to establish an initial correspondence between the digital space and the physical space, so as to provide basic data for subsequent sequential flow, single-piece-level transfer binding, and heterogeneous material shunting and pressing.

[0056] In one embodiment, after receiving a patient order, the manufacturing execution system first generates a model task set based on the instrument composition corresponding to that patient. The model task set may include molded models corresponding to multiple standard orthodontic appliances, as well as molded models corresponding to retainers, accessory templates, or other shell-shaped dental instruments. The manufacturing execution system schedules the model task set according to patient affiliation, instrument attributes, printing capacity, and subsequent process cycles. In a preferred embodiment, the manufacturing execution system allocates models according to patient order, prioritizing models from the same patient within consecutive or adjacent areas of the same printing plate. In other embodiments, it is also permissible for a patient to be allocated across multiple printing plates, or for multiple patients to share the same printing plate, but the system still maintains a consistent correspondence between each model and its associated patient, instrument attributes, and printing position through a unique digital identifier.

[0057] Furthermore, the manufacturing execution system executes a nearest-neighbor nested scheduling algorithm to spatially arrange the models to be printed on the 3D printing platform. The goal of this algorithm is to ensure that multiple models from the same case are as physically adjacent as possible while maintaining platform utilization, thereby reducing order disruptions and sorting pressure caused by model mixing during subsequent processing. Through this method, Figure 2 Multiple models corresponding to the same case can form a continuous block or several adjacent sub-blocks on the printing base plate; when multiple cases share the same base plate, the models of different cases form distinct regional arrangements.

[0058] In one embodiment, to ensure consistency between the digital sequence and the physical flow, the manufacturing execution system records the coordinate position of each model on the printing plate, its associated case information, and instrument attribute information after production scheduling is completed, and generates corresponding plate-level task data. The plate-level task data preferably includes, but is not limited to: printing plate number, model number, model spatial coordinates, instrument type, subsequent membrane type, and model sorting information. Figure 2 The system can schematically associate the location point corresponding to each model with its logical identity, thereby forming an initial mapping relationship between "model location - model identifier - instrument attribute". This mapping relationship can be maintained by a unified ID management mechanism, so that even if the model is produced in parallel across multiple printers and multiple boards, the logical order can still be kept consistent in subsequent processes.

[0059] In one embodiment, after 3D printing is completed, the printed base plate, along with multiple molded models on it, is sent as a whole to the subsequent process. Preferably, the base plate does not leave the carrier during the entire front-end production line and maintains its original arrangement order. The automated guided vehicle can pick up the plates sequentially according to the production schedule, so that the physical flow sequence is synchronized with the digital production schedule sequence.

[0060] like Figure 3 As shown, in one embodiment, Figure 3 This invention illustrates the single-piece transfer and buffer carrier binding method after post-processing of the molded models. This stage, located after 3D printing and before the lamination process, is mainly used to convert multiple molded models from a plate-level arrangement on the printing base to a single-piece positioning state on the buffer carrier while maintaining the physical order of the previous stages. Simultaneously, it establishes the correspondence between model identifiers, buffer carrier identifiers, and grid position information, thereby providing a precise single-piece data foundation for subsequent lamination sorting, identification coding, and asynchronous buffer sorting.

[0061] In one embodiment, the printed base plates are transported to the post-processing equipment by an automated guided vehicle (AGV) according to a predetermined production sequence. Preferably, the AGV picks up the plates sequentially according to the production schedule provided by the Manufacturing Execution System (MES), ensuring that the physical flow sequence of the base plates is consistent with their digital sequence. Furthermore, before and during the post-processing stage, the printed base plates preferably remain attached to the carrier, and the molded models on the base plates maintain their original arrangement, thereby avoiding additional risks of misordering introduced by premature disassembly in the earlier stages. The base plates preferably maintain their original arrangement throughout the entire earlier production line, and the system tracks the position of each base plate in real time by scanning a barcode or reading the base plate's identification mark.

[0062] In one embodiment, a base plate identification reading module is provided at the entrance of the post-processing equipment, preferably a reader for reading the first RFID tag on the printed base plate. When the base plate enters the post-processing equipment, the reading module first reads the base plate identification and confirms with the manufacturing execution system the production scheduling task, model position, and model identification information corresponding to the base plate. Subsequently, the post-processing equipment sequentially performs spin-drying, separation, and post-curing processes. The spin-drying process removes uncured residual material from the surface of the molded model; the separation process detaches the molded model from the printed base plate; and the post-curing process further cures the model to improve its structural stability. Preferably, the spin-drying process can employ forward and reverse flipping combined with variable-speed centrifugal control to improve waste liquid separation efficiency; the separation process can employ a porous base plate combined with a synchronous lifting method using an ejector pin array to achieve whole-plate demolding without disrupting the original sequence.

[0063] In one embodiment, after post-processing, multiple molded models enter a buffer transfer area. This area is equipped with a transfer robot, a vision recognition module, and a multi-compartment buffer carrier. The transfer robot sequentially grasps the post-processed molded models according to the model coordinate order recorded by the manufacturing execution system. The vision recognition module is preferably an industrial camera located on the side of the robot, which identifies a first model identification feature on the model during the robot's grasping or transfer process. Preferably, the first model identification feature is a raised unique identification code formed integrally with the model during the printing stage, so that each molded model can be individually identified and confirmed before entering the buffer carrier.

[0064] Furthermore, the multi-compartment buffer carrier is a standardized carrier with multiple independent compartments, and its bottom is equipped with a second carrier identifier, preferably a second RFID tag. After the transfer robot identifies the first model identifier feature of the current model, it places the model in the designated compartment of the buffer carrier, and the manufacturing execution system simultaneously records the identification result corresponding to the model, the current buffer carrier number, and the compartment position information, thereby establishing a one-to-one binding relationship between the three. Through this binding relationship, the system can be further transformed from the original base plate level tracking to single-piece level tracking, that is, each model has a unique "model identifier - carrier identifier - compartment position" correspondence. In a preferred embodiment, the buffer carrier can adopt a grid buffer disk structure with 4 rows and 4 columns, a total of 16 compartments, with a second RFID tag embedded in the bottom, and the models are placed sequentially compartment by compartment.

[0065] like Figure 4 As shown, in one embodiment, Figure 4 The diagram illustrates the structure of the dual-station molding unit in this invention. Located after the buffer transfer unit and before the identification and coding unit, the dual-station molding unit receives the molded models that have completed single-piece level binding and performs thermoforming at different molding stations according to the instrument attributes and diaphragm types corresponding to each molded model. Unlike existing molding devices that are only applicable to a single diaphragm shape, the molding unit in this embodiment has at least two molding stations connected in parallel within the same device, enabling shell-shaped dental instruments corresponding to different diaphragm types to be processed continuously along the same main line.

[0066] In one embodiment, the dual-station molding unit includes an input channel, a reading module, a diversion mechanism, a first molding station, a second molding station, and an output channel. The input channel receives the molding model transported by a buffer carrier; the reading module, located at the input channel, reads the second carrier identifier on the buffer carrier; the diversion mechanism, located between the input channel and each molding station, feeds different molding models into their respective molding stations according to predetermined rules; the first and second molding stations are connected in parallel and are respectively connected to the output channel; the output channel outputs the completed hot-pressed model and film assembly to subsequent processes. With this structural arrangement, Figure 4 The dual-station lamination unit shown is characterized by a structure of "single input, parallel processing, and unified output".

[0067] Furthermore, the reading module is preferably an RFID reader, used to read the second RFID tag set on the bottom of the buffer carrier and send the reading result to the manufacturing execution system. Based on the model identifier, grid position information, and instrument attributes corresponding to the buffer carrier, the manufacturing execution system determines the instrument type and target membrane type of the current membrane model to be pressed, and outputs corresponding diversion commands to the diversion mechanism.

[0068] In one embodiment, the diversion mechanism preferably includes a diversion robot or other controllable pick-and-place mechanism. This diversion mechanism retrieves the molded models one by one according to the order of their slots in the buffer carrier, and sends the current molded model to the first or second molding station according to the diversion command issued by the manufacturing execution system. Preferably, the relative positional relationship between the diversion mechanism, the input channel, and each molding station is set such that the diversion mechanism is located between the end of the input channel and the front ends of the two molding stations, so that the model sent in by the input channel can be diverted and selected before reaching the molding station. In this way, Figure 4 The diversion mechanism shown serves both as a material transfer mechanism and a process path selection mechanism.

[0069] In one embodiment, the first pressing station is a roll material station for processing a first type of diaphragm. The first type of diaphragm is preferably a continuously supplied roll material, such as a roll material used for thermoforming standard orthodontic appliances. Accordingly, the first pressing station includes a roll material feeding mechanism, a roll material heating mechanism, and a roll material pressing mechanism. The roll material feeding mechanism is used to provide the target diaphragm from a roll material roller or other continuous feeding unit; the roll material heating mechanism is used to preheat or soften the roll material diaphragm; the roll material pressing mechanism is used to apply pressure between the heated roll material diaphragm and the forming mold, causing the diaphragm to adhere to the mold surface to complete the thermoforming process.

[0070] In one embodiment, the second molding station is a sheet molding station for processing a second type of sheet. The second type of sheet is preferably a discretely supplied sheet, such as sheets of different thicknesses or materials, used for thermoforming retainers, accessory templates, or other shell-shaped dental instruments. Accordingly, the second molding station includes a sheet material hopper, a sheet suction mechanism, a sheet heating mechanism, and a sheet molding mechanism. The sheet material hopper stores one or more sheet specifications; the sheet suction mechanism retrieves the target sheet from the corresponding material location; the sheet heating mechanism heats and softens the retrieved sheet; and the sheet molding mechanism presses the heated sheet against the surface of the molding model under pressure to complete the thermoforming process. The system can automatically identify the required material type based on the model ID and call the corresponding hopper for molding; therefore, in this embodiment, the second molding station preferably has the ability to automatically switch between different sheet specifications.

[0071] Furthermore, the first and second molding stations share the same input and output channels. In other words, the molded models from the buffer transfer unit do not need to enter two separate production lines. Instead, they first enter the dual-station molding unit via a common input path, and then are sent to the corresponding stations by the diversion mechanism. After molding is completed, they rejoin the common output path.

[0072] like Figure 5 As shown, in one embodiment, when the shell-shaped dental instrument corresponding to the current molding model is a standard orthodontic appliance, the manufacturing execution system outputs a first type of diversion command, causing the diversion mechanism to send the model into the first pressing station. The first pressing station is preferably a roll material station, and its operation includes: a roll material feeding mechanism providing a target roll material film; a roll material heating mechanism heating the roll material film to a state suitable for hot pressing; and a roll material pressing mechanism applying pressure to the heated roll material film to adhere it to the surface of the molding model. More specifically, preferred parameters include, for example, using a 0.76mm thick PETG roll material film; the roll material pressing mechanism performing hot pressing under a positive pressure of approximately 0.4MPa to 0.6MPa and maintaining a predetermined holding pressure time to ensure the film is stably adhered to the model surface after cooling.

[0073] In one embodiment, when the shell-shaped dental instrument corresponding to the current molding model is a retainer, accessory template, or other instrument requiring sheet molding, the manufacturing execution system outputs a second type of diversion command, causing the diversion mechanism to send the model to the second molding station. The second molding station is preferably a sheet molding station, and its operation includes: the sheet material hopper selecting a target specification sheet according to control commands; the sheet material suction mechanism removing the sheet from the corresponding material location; the sheet material heating mechanism heating and softening the sheet; and the sheet molding mechanism completing the hot-pressing bonding of the molding model. Since the sheet molding station can store sheets of various materials or thicknesses, the manufacturing execution system can further issue hopper switching commands within this station, enabling the same equipment to sequentially process different sheets required for different functional instruments. The system can automatically identify the required material type based on the model ID and call the corresponding hopper for molding, thereby meeting the continuous production needs of multiple instruments under the same case or the same preset grouping object.

[0074] Furthermore, the standard orthodontic appliance model enters the first pressing station for roll pressing, while the retainer model, accessory template model, or other sheet instrument model enters the second pressing station for sheet pressing.

[0075] In one embodiment, regardless of whether the current molding model enters the first or second molding station, the basic mechanism of thermoforming is the same: the heated and softened membrane is adhered to the surface of the molding model under pressure, causing the membrane to replicate the outer surface shape of the molding model, thereby forming a corresponding shell-shaped dental instrument semi-finished product. Preferably, during this thermoforming process, the first model identification feature set on the molding model also participates in the molding as a geometric feature, and a corresponding inherited identification feature is formed on the membrane. Because this physical inheritance process will... Figures 6a to 6c This will be further developed in the middle, therefore Figure 5 This can be understood as the natural result after the diversion and pressing action is completed. That is, although different films come from different stations, they all retain the identity characteristics corresponding to the original molding model after the hot pressing is completed.

[0076] In one embodiment, after each station completes the hot pressing of the current model, the formed "model-film assembly" is output from the corresponding station and re-converges into the unified output channel of the dual-station lamination unit. That is, although different stations have different processing paths, they return to the same main line at the equipment exit, providing a unified input for subsequent identification, coding, and cutting processes. This "unified input at the front end—attribute-based branching in the middle—unified convergence at the back end" working principle is one of the key features that distinguishes this invention from the traditional method of setting up multiple independent lamination branches. The two stations share the same input and output channels, which aims to avoid the increased manual merging and sorting pressure caused by the separate processing of different materials in existing technologies.

[0077] like Figures 6a to 6c As shown, in one embodiment, the present invention pre-sets a first model identification feature on the molded model, and utilizes the shape replication effect of the diaphragm on the surface of the molded model during the hot pressing process to form a corresponding second inherited identification feature on the diaphragm, thereby realizing the physical inheritance of identity information from the model to the diaphragm. This physical inheritance process does not require re-assigning a temporary identity identifier through an independent marking device after pressing; instead, it directly utilizes the physical process of hot pressing itself to complete the transfer of identity features, providing intermediate identification basis for subsequent identification verification and traceability coding.

[0078] In one embodiment, such as Figure 6a As shown, the first model identification feature is set in a predetermined area of ​​the molded model. Preferably, the predetermined area is a non-functional area that does not affect the wearing performance and clinical function of the target shell-shaped dental instrument, such as the area below the gingival line, the blank area of ​​the positioning structure, or other locations suitable for forming geometric features. The first model identification feature is preferably a raised identification feature integrally printed with the molded model, and more preferably a raised unique identification code. The preferred form is a raised UID composed of letters and numbers, which is added to the surface of the model when generating the three-dimensional digital model of each model and is formed synchronously with the model during the three-dimensional printing process. Specifically, the character height can be 0.5 mm, the width can be 0.3 mm, and the raised height can be 0.2 mm, but the present invention is not limited to this specific size, as long as an identifiable inherited identification feature can be formed after subsequent hot pressing.

[0079] Furthermore, Figure 6a The raised identification feature not only serves as the model's identity marker but also functions as the geometric element for subsequent hot-press replication of the parent model. In other words, this raised identification feature exists directly on the model's surface as part of the model's geometry. Therefore, when the diaphragm softens upon heating and adheres to the model's surface, this raised geometric feature is replicated along with other surface features of the model. Because this identification feature is part of the model's inherent geometry, its identity information can be transferred to the diaphragm via geometric imprinting, unlike traditional recoding processes that rely on backend software to infer which model the current diaphragm corresponds to.

[0080] In one embodiment, such as Figure 6b As shown, after the heated and softened diaphragm is placed on the surface of the molding model under pressure and thermoforming is completed, the diaphragm and the molding model form an uncut assembly. At this point, the diaphragm has replicated the overall outer surface shape of the molding model, and simultaneously, corresponding to... Figure 6aThe raised markings indicate the location of a localized deformation area. In other words, before the film is cut after molding, the inner side of the film already carries the geometric imprint formed by the raised markings of the molding model. However, this geometric imprint is still within the model-film assembly and has not yet been identified and separated by cutting.

[0081] Furthermore, Figure 6b The formation mechanism of the hot-pressed state shown is as follows: After the diaphragm is heated to a plastic state by a heating mechanism, it is pressed onto the surface of the molding mold under air pressure or mechanical pressure, thereby conforming to the shape of the mold. When the diaphragm flows through or covers... Figure 6a When the raised markings indicate a feature area, because this area has a local protrusion relative to the model surface, the diaphragm will undergo local deformation at the corresponding position under pressure and retain this deformation result. For the roll forming station and the sheet forming station, the diaphragm supply methods differ, but as long as the hot pressing process allows the diaphragm to replicate the geometric features of the model surface, the same physical inheritance result can be produced. In one embodiment, the roll forming station can use a positive pressure of approximately 0.4 MPa to 0.6 MPa for hot pressing and maintain a predetermined holding time, allowing the diaphragm to cool and stably adhere to the model surface.

[0082] In one embodiment, such as Figure 6c As shown, when Figure 6b After the assembly shown has cooled and been demolded, the inner side of the diaphragm corresponds to Figure 6a A second inherited identifier feature is formed at the location of the raised identifier feature shown. Preferably, the second inherited identifier feature is a recessed inherited identifier feature, more preferably a unique identifier for a recessed indentation. That is to say, Figure 6a The raised marking feature in Figure 6c The UID is represented by an indentation mark on the inner side of the diaphragm, which is a feature with opposite geometry. The UID character, which was originally raised on the model, naturally forms an indentation mark at the corresponding position on the diaphragm under pressure. After cooling and demolding, the clear indentation mark UID is retained on the inner side of the diaphragm.

[0083] Furthermore, Figure 6c The recessed inherited identifier feature shown provides intermediate verification for subsequent identification and coding processes. This inherited identifier feature directly originates from... Figure 6a The model's geometric features are shown, and its formation process is integrated throughout. Figure 6b The pressing action shown in the diagram inherently ensures a natural consistency between the membrane and the original model. Subsequent identification and coding units only need to recognize this inherited identifier on the membrane and compare it with the model identifier and production scheduling information recorded in the manufacturing execution system to confirm the correspondence between the current membrane and the original model. Thus, this invention does not require "guessing" or "inferring" which model the current membrane originated from after pressing; instead, it completes the identity transfer through an intermediate geometric feature naturally formed by hot pressing replication.

[0084] like Figure 7 As shown, in one embodiment, Figure 7 This invention illustrates the end-to-end identification transfer chain and traceability binding relationship. The identification transfer chain spans multiple processes, including production scheduling, printing, post-processing, buffer transfer, lamination, identification coding, and cutting. Its purpose is to ensure that each shell-shaped dental instrument possesses a traceable identity from the digital model stage, and this identity is continuously transferred in subsequent processes through physical identification and data binding until a permanent traceability identifier is formed on the final product. Preferably, this identification transfer chain includes five levels: base plate level identification, model level identification, carrier level identification, product-level intermediate inherited identification, and shipping level identification.

[0085] In one embodiment, the baseplate-level identifier is a first baseplate identifier, preferably a first RFID tag, affixed to the printing baseplate. This baseplate-level identifier is bound to the task data of the current printing batch by the manufacturing execution system during the production scheduling phase, and is used to characterize the set of models, model location distribution, case attribution, and device attributes carried by a single printing baseplate. In other words, Figure 7 The first layer of the identification chain begins with a batch-level physical carrier identifier associated with the printing substrate. Through this starting point, subsequent equipment can retrieve the production scheduling and sequence information associated with the substrate after reading its identifier, thus achieving board-level tracking.

[0086] Furthermore, the model-level identifier is a first model identification feature set on the surface of each molded model, preferably a raised unique identification code integrally printed with the molded model. This model-level identifier is embedded in the molded model during the model generation and printing stages, used to identify the unique identity of each individual model. Compared to the base plate-level identifier, the model-level identifier has a finer granularity, its function being to further distinguish multiple models originally belonging to the same base plate into individually identifiable individuals. Therefore, in Figure 7 In the identification transmission chain shown, the base plate level identification mainly undertakes batch positioning and overall tracking functions, while the model level identification mainly undertakes individual item identification functions. Both are established simultaneously during the production scheduling and printing stages, together forming the front-end foundation for subsequent traceability.

[0087] In one embodiment, after printing is completed and the process enters the post-processing and cache transfer stage, the carrier-level identifier begins to participate in the traceability chain. The carrier-level identifier is preferably a second RFID tag disposed on the bottom of a multi-compartment cache carrier. When the transfer robot places the post-processed molded model sequentially into the designated compartments of the cache carrier, the vision recognition module reads the unique raised identification code on the model, and the manufacturing execution system then binds this identification result with the cache carrier number and the specific compartment position. Thus, Figure 7The third layer of the identification chain is established, forming a single-piece level correspondence of "model-level identifier—vehicle-level identifier—grid location". Through this process, the present invention is... Figure 2 Transition from board-level tracing to Figure 3 It enables single-item-level tracking and gives each model a precisely located position in physical space.

[0088] In one embodiment, the fourth layer identifier is a product-level intermediate inherited identifier, which is formed on the diaphragm during the hot-pressing process from the first identifier feature on the molded model, and serves as the verification basis for subsequent identification and coding. Further, after the hot-pressed model-diaphragm assembly enters the identification and coding process, Figure 7 The fifth layer of the identification chain is formed. Specifically, the identification and coding unit identifies the unique identification code of the indentation on the diaphragm. After receiving the identification result, the manufacturing execution system compares and verifies it with the production sequence information, model attribute information and case attribution information recorded in the database. After verification, the system controls the marking device to form the final traceability mark at the designated position on the diaphragm, preferably a DM code containing patient information, number of treatment steps, production batch and other information.

[0089] In one embodiment, Figure 7 The five-level identification chain shown can be summarized as follows: the first layer is Plate-RFID board-level identification, the second layer is raised UID model-level identification, the third layer is Tray-RFID carrier-level identification, the fourth layer is recessed indented UID product-level intermediate inheritance identification, and the fifth layer is DM code shipping-level identification.

[0090] like Figure 8 As shown, in one embodiment, Figure 8 This illustrates the asynchronous buffer sorting and merging / release states in this invention. After being cut, the shell-shaped dental instruments are scanned and enter the corresponding buffer channel according to the merging object. When all shell-shaped dental instruments under a certain merging object have arrived, the manufacturing execution system triggers the merging / release. When a certain merging object has missing shell-shaped dental instruments, the arrived shell-shaped dental instruments enter a logical suspension state, which is released after the missing instruments are replenished, and the merging / output is then executed.

[0091] In one embodiment, the asynchronous buffer sorting unit includes multiple independently controlled buffer channels, a barcode scanner, and a sorting robot. Before entering the buffer channel, the cut shell-shaped dental instruments are scanned by the barcode scanner to read their final traceability identifier or auxiliary identification identifier. The manufacturing execution system then controls the sorting robot to deliver the instrument to the corresponding buffer channel based on the case attribution information, instrument type information, or preset merging rules carried in the identifier. In this way, although multiple instruments from the same case or under the same preset merging object may arrive at different times, they are always grouped under the same merging logic that the system can recognize during the buffer sorting stage.

[0092] Furthermore, when the manufacturing execution system detects that all target instruments under a certain case or a pre-defined merging object have arrived at the corresponding buffer channel, the system triggers a merging release command, causing all instruments under that case or pre-defined merging object to be uniformly collected and sent to the packaging or subsequent output station. In this state, Figure 8 The buffer channel shown primarily serves as a temporary collection point; once all instruments are collected, they can be released as a whole. In a preferred embodiment, when all components of the current case have arrived, a collection order command is triggered, automatically collecting and delivering all orthodontic appliances, accessory templates, and retainers for that case to the packaging station.

[0093] In one embodiment, when the manufacturing execution system detects a missing device in a case or a pre-defined merged object, the system marks the arrived devices as logically suspended in the corresponding buffer channel. Logical suspension means that although the devices have arrived at the buffer position, they are not released externally or mixed with other cases or pre-defined merged objects until the missing device is replaced. Simultaneously, this logical suspension state does not prevent the main line from processing other devices; other buffer channels can still operate normally. In this way, the present invention confines "missing device waiting" to a specific buffer channel or a specific logical merged object, preventing the entire main line from stalling due to a single missing device.

[0094] Furthermore, Figure 8 The asynchronous buffer sorting and merging release status shown does not require all devices to arrive strictly simultaneously, but allows different devices to arrive sequentially within a certain time window. This is as long as the device identification information is verified. Figure 7 The identification chain shown has been reliably established, and the manufacturing execution system can determine when to release, when to suspend, and when to wait for replenishment based on the arrival status, missing parts status, and merging rules.

[0095] like Figure 9 As shown, in one embodiment, Figure 9 This diagram illustrates the supplementary piece insertion and out-of-order self-healing control method of this invention. The figure primarily describes how the system restores the original merging relationship when a molded model or instrument is defective, damaged, or omitted in a previous process, through supplementary piece rearrangement, buffer suspension, and subsequent replenishment. In traditional production methods, supplementary pieces typically lag significantly behind the original batch schedule, causing the same item to wait for a long time at the sorting end. This invention, through a combination of proximity insertion and asynchronous suspension, limits the impact of supplementary pieces on the overall line delivery rhythm to a localized range.

[0096] In one embodiment, when the manufacturing execution system detects that a model is deemed unqualified during post-processing, molding, identification, cutting, or quality inspection, a corresponding replacement order is immediately generated. Further, before the replacement item returns to the sorting end, other instruments belonging to the same case or the same pre-defined merging object can first enter the corresponding buffer channel and be marked as logically suspended. When the replacement item arrives at the asynchronous buffer sorting unit after re-production, the manufacturing execution system guides it to the corresponding buffer channel based on its traceability identifier and releases the logical suspension status of that channel, allowing the previously arrived instruments and the replacement item to re-merge, followed by merging and release. In a preferred embodiment, after a model becomes unqualified, the remaining completed components are suspended in buffer channel 3; once the replacement item arrives again, the system releases the suspension and completes the merging and packaging of all components.

[0097] In one embodiment, Figure 9 The replacement order and disordered self-healing control shown can also be combined with the dedicated guidance path for rework cases. After a rework case or replacement item re-enters the production line, it can be identified by scanning a code and guided to the corresponding exit or corresponding buffer path, preventing it from mixing into the main process of other cases.

[0098] like Figure 10 As shown, in one embodiment, the present invention is applicable to shell-shaped dental instruments obtained by thermoforming a diaphragm onto a dental molding model, the shell-shaped dental instruments including clear aligners, retainers, accessory templates, and other dental instruments with shell-shaped covering structures.

[0099] In one embodiment, different shell-shaped dental instruments may correspond to different diaphragm types; wherein, standard orthodontic appliances are preferably formed by thermoforming rolled diaphragms, and retainers, accessory templates or other shell-shaped dental instruments are preferably formed by thermoforming sheet diaphragms.

[0100] like Figure 11 As shown, in one embodiment, the manufacturing execution system adjusts the task release rhythm, buffer carrier transfer rhythm, and / or pressure film diversion rhythm of at least one upstream process based on the status information in the asynchronous buffer sorting unit, so as to ensure that the number of objects in the pending merging state does not exceed a preset threshold N. The status information includes one or more of the following: buffer channel occupancy status, merging object integrity status, missing part status, and suspended status.

[0101] In one embodiment, the manufacturing execution system continuously receives status information from the asynchronous buffer sorting unit. This status information includes at least the occupancy status of each buffer channel, the integrity status of each medical record or pre-defined merging object, the missing item status, and the pending status. Based on this status information, the manufacturing execution system can adjust the task release rhythm of at least one upstream process. For example, when the number of objects to be merged continues to increase, or when certain buffer channels are suspended for extended periods, the system can reduce the new task release speed, adjust the buffer carrier transfer cycle, or optimize the diversion execution sequence of the dual-station lamination unit to prevent newly generated instruments from continuing to accumulate disorderly at the end.

[0102] Furthermore, Figure 11 The rhythmic feedback control shown can be understood as a closed-loop control around an upper limit on the quantity to be merged. This upper limit can be determined by a combination of factors, including buffer channel capacity, packaging station processing capacity, replenishment tolerance time window, or overall production line throughput target.

[0103] In one embodiment, a shell-shaped dental instrument manufacturing plant deployed the automated production system described in this invention. The overall implementation process of this invention will now be further explained using a typical case order as an example. This case order includes a 20-step standard orthodontic appliance, one set of accessory templates, and one set of retainers. The standard orthodontic appliance is formed by thermoforming rolled film, while the accessory templates and retainers are formed by thermoforming sheet film. Two molded models are provided for each step of the upper and lower jaws, totaling 44 jaw models.

[0104] The Manufacturing Execution System (MES) first receives the case order information and identifies the case as a merged object. Then, the MES generates a production schedule based on the attributes of each instrument under that case, assigning the 44 dental models to one or more printing bases in a nearest-neighbor manner, and establishing a binding relationship between the printing base identifier and the model position and instrument attributes. Simultaneously, when generating the 3D model data for each molded model, a first identification feature is formed in the non-functional areas of the model to serve as the basis for subsequent cross-process continuous identity mapping.

[0105] Furthermore, the 3D printing unit completes the printing of each molded model according to the production schedule, and the automated guided vehicle transports the printing base plate to the post-processing unit in the order given by the manufacturing execution system. After the post-processing unit completes spin drying, separation and post-curing, the buffer transfer unit picks up the molded models one by one in a predetermined order and transfers them to a buffer carrier with multiple slots. At the same time, it establishes a binding relationship between the first identification feature, the buffer carrier identification and the slot position information, thereby realizing the transformation from base plate-level flow to single-piece-level flow.

[0106] Furthermore, the molding unit adopts a dual-station molding structure with shared input and output channels. After reading the cache carrier identifier, the manufacturing execution system controls the shunt mechanism to select the molding path according to the instrument attributes corresponding to the model. For the molding model corresponding to the standard orthodontic appliance, the shunt mechanism sends it to the first molding station for thermoforming using a roll film; for the molding models corresponding to accessory templates and retainers, the shunt mechanism sends them to the second molding station for thermoforming using sheet films of different specifications. Thus, shell-shaped dental instruments corresponding to different film types under the same grouping object can be classified and molded under a shared production path without having to be processed separately off the main line.

[0107] Furthermore, during the hot pressing process, the first identification feature set on the molding model forms a second identification feature on the diaphragm, thereby achieving physical inheritance of identity information from the molding model to the diaphragm. After the molding is completed, the model-diaphragm assembly enters the identification and coding unit, which identifies the second identification feature and verifies it based on the aforementioned binding relationship. Upon successful verification, a final traceability identifier is formed at a predetermined position on the diaphragm. Subsequently, the cutting unit cuts the diaphragm to form the target shell-shaped dental instrument.

[0108] Under normal production conditions, the cut shell-shaped dental instruments enter the asynchronous buffer sorting unit and then proceed to the corresponding buffer channel according to the merged objects. When all 44 components of the case order have arrived, the manufacturing execution system triggers the merge release, which gathers and outputs the 20-step standard orthodontic appliance, one accessory template, and one retainer, thereby completing the controlled output of the merged objects.

[0109] In abnormal situations, if a molded model is deemed unqualified during post-processing, lamination, identification, cutting, or quality inspection, the manufacturing execution system generates a corresponding replacement task. Preferably, a proximity insertion strategy is used to insert the replacement task into the nearest available printing batch. Simultaneously, other completed shell-shaped dental instruments under this merged object first enter the corresponding buffer channel and are in a logically suspended state. Once the replacement piece has completed printing, post-processing, lamination, identification coding, and cutting, it arrives at the asynchronous buffer sorting unit. The manufacturing execution system guides it to the corresponding buffer channel, releases the logical suspension, and resumes the merge release. Therefore, even with rework, replacement orders, and arrival time differences, this invention can still maintain the integrity of the merged object and complete the final output.

Claims

1. An automated production method for shell-shaped dental instruments, characterized in that, Using the merged object as the control unit, the production flow and output process of shell-shaped dental instruments from molding model to finished product is automatically organized. By maintaining the continuity of cross-process identification mapping and rhythmic coordination according to the merging status, shell-shaped dental instruments corresponding to different molding needs can complete classification molding and merging output under a shared production path.

2. The automated production method for shell-shaped dental instruments according to claim 1, characterized in that, include: S1. Receive order information and determine the objects to be merged based on the order information; S2. Generate production scheduling tasks for multiple molding models, allocate multiple molding models corresponding to the merged object to one or more printing base plates according to predetermined rules, establish the binding relationship between the printing base plate identifier and the model position and instrument attributes, and form a first identification feature as the model identity identifier on the molding model. S3. Perform 3D printing and post-processing on the multiple molded models; S4. Transfer the post-processed molded model to the buffer carrier in a predetermined order, and establish the binding relationship between the first identification feature, the buffer carrier identifier and the grid position information; S5. The molding model is sent into the pressing unit, and the molding model is diverted to at least two pressing stations for hot pressing according to the instrument properties. The at least two pressing stations share the input channel and the output channel. S6. During the hot pressing process, the first marking feature set on the molding model is used to form a second marking feature on the film; S7. Identify the second identification feature and verify it based on the aforementioned binding relationship. After the verification is passed, assign a final traceability mark to the diaphragm and cut it to form a shell-shaped dental instrument. S8. The cut shell-shaped dental instruments are sent to the asynchronous buffer sorting unit, cached according to the merged objects, and merged output is performed when the merged objects are complete. When the merged objects are missing parts, the logic is suspended and waited for the missing parts to be replenished.

3. The method according to claim 2, characterized in that, The merging object is a single case or a combination of multiple cases for unified merging output; the multiple molding models are arranged in a spatial proximity manner in a continuous or adjacent area of ​​the same printing base during production scheduling.

4. The method according to claim 2, characterized in that, The printing base plate identifier is a first radio frequency identification tag set on the printing base plate, and the buffer carrier identifier is a second radio frequency identification tag set on the buffer carrier.

5. The method according to claim 2, characterized in that, The first identification feature is a unique identification feature of a protrusion set in the non-functional area of ​​the molding model, and the second identification feature is an inherited identification feature of a depression formed on the inner side of the diaphragm.

6. The method according to claim 2, characterized in that, The at least two lamination stations include a first lamination station for processing roll films and a second lamination station for processing sheet films, wherein the second lamination station calls sheet films of different materials and / or different thicknesses according to the instrument properties.

7. The method according to claim 2, characterized in that, The identification of the first identification feature and / or the second identification feature is performed using a visual recognition module, and after the second identification feature is verified, a final traceability mark is formed at a predetermined position on the membrane.

8. The method according to claim 2, characterized in that, The asynchronous buffer sorting unit includes multiple independently controlled buffer channels; when there are defective or missing parts during the production process, a replacement order is generated and the replacement order is preferentially inserted into the available printing batch closest to the current time. The manufacturing execution system adjusts the task release rhythm, buffer carrier transfer rhythm and / or pressure film diversion rhythm of at least one upstream process based on the status information of the asynchronous buffer sorting unit, so as to ensure that the number of objects to be merged is not greater than a preset threshold N.

9. An automated production system for shell-shaped dental instruments, characterized in that, Using the merged object as the control unit, it is used to automate the production flow and output process of shell-shaped dental instruments from molding model to finished product. By maintaining the continuity of cross-process identification mapping and rhythmic coordination according to the merged state, shell-shaped dental instruments corresponding to different molding needs can complete classification molding and merged output under a shared production path.

10. The automated production system for shell-shaped dental instruments according to claim 9, characterized in that, It includes a manufacturing execution system, a 3D printing unit, a post-processing unit, a buffer transfer unit, a molding unit, an identification and coding unit, a cutting unit, and an asynchronous buffer sorting unit; The manufacturing execution system is used to receive order information, determine the objects to be merged, generate production scheduling tasks, establish identifier binding relationships, and issue control commands. The cache transfer unit is used to transfer the post-processed molded model to the cache carrier in a predetermined order, and to establish a binding relationship between the first identification feature, the cache carrier identifier and the grid position information; The pressing unit includes at least two pressing stations that share an input channel and an output channel, and is used to perform hot pressing molding according to the instrument properties corresponding to the molding model, and to form a second identification feature on the molding model onto the diaphragm. The identification and coding unit is used to identify the second identification feature and perform verification based on the identification binding relationship. After the verification is passed, the final traceability identification is formed. The asynchronous buffer sorting unit is used to cache the cut shell-shaped dental instruments according to the merged object, and to perform merge output when the merged object is complete, and to perform logical suspension and wait for the missing parts when the merged object is missing.

11. The system according to claim 10, characterized in that, The buffer transfer unit includes a transfer robot, a vision recognition module, and a multi-compartment buffer carrier; the pressing unit includes a first pressing station for processing roll film and a second pressing station for processing sheet film, and the second pressing station includes a sheet material bin that can switch between different sheet specifications.

12. The system according to claim 10, characterized in that, The manufacturing execution system is also used to adjust the task release rhythm, buffer carrier transfer rhythm and / or pressure film diversion rhythm of at least one upstream process according to the status information of the asynchronous buffer sorting unit, so as to ensure that the number of objects to be merged is not greater than a preset threshold N.

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